Ford Freestar, Monterey 2004-2006

Valve Covers

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Removal & Installation



Left Side

WARNING
During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

  1. Remove the 2 nuts and position the auxiliary relay box aside.
  2.  
  3. Remove the oil level indicator tube bolt and position aside the oil level indicator tube.
  4.  
  5. Disconnect the crankcase vent hose from the left side valve cover.
  6.  
  7. Disconnect the crankcase vent hose electrical connector.
  8.  
  9. Remove the 3 bolts and the 2 stud bolts from the left side valve cover.
  10.  
  11. Remove the left side valve cover.
    NOTE
    Do not discard the gasket. It may be reused if it is not damaged.

  12.  
  13. Remove and inspect the left side valve cover gasket.

    Click image to see an enlarged view

    Fig. Exploded view of the left side valve cover-Oil level indicator tube bolt (1), oil level indicator tube (2), crankcase vent hose (3), crankcase vent hose electrical connector (4), valve cover bolts (5), valve cover stud bolt (6), left side valve cover (7), valve cover gasket (8)

  14.  

To install:

  1. Position the valve cover gasket.
  2.  
  3. Install the valve cover and secure with the retainers. Tighten to 89 inch lbs. (10 Nm).
  4.  
  5. Connect crankcase vent hose electrical connector.
  6.  
  7. Connect the crankcase vent hose to the LH valve cover.
  8.  
  9. Install the oil level indicator tube and tighten the bolt to 89 inch lbs. (10 Nm).
  10.  
  11. Place the auxiliary relay box in position and secure with the 2 nuts. Torque the nuts to 89 inch lbs. (10 Nm).
  12.  

Right Side

WARNING
During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

  1. Remove the ignition coil, as outlined in Engine Electrical.
  2.  
  3. Remove the nuts and the fresh air inlet duct.
  4.  
  5. Disconnect the crankcase vent hose.
  6.  
  7. Remove the 2 bolts and the 3 stud bolts from the RH valve cover.
  8.  
  9. Remove the RH valve cover.
  10.  
  11. NOTE: Do not discard the gasket. It may be reused if it is not damaged.
  12.  
  13. Remove and inspect the RH valve cover gasket.

    Click image to see an enlarged view

    Fig. Exploded view of the right side valve cover-Crankcase vent hose (1), Valve cover bolts (2), valve cover stud bolts (3), right side valve cover (4), valve cover gasket (5)

  14.  

To install:

  1. Position the valve cover gasket.
  2.  
  3. Install the right side valve cover and tighten the retainers to 89 inch lbs. (10 Nm).
  4.  
  5. Connect the crankcase vent hose.
  6.  
  7. Install the fresh air inlet duct. Tighten the nuts to 44 inch lbs. (5 Nm).
  8.  
  9. Install the ignition coil, as outlined in Engine Electrical.    
  10.  

 
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